renegade budget boost instructions - teraflex · 2017. 10. 23. · 1 revision b 999259 renegade...

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Renegade Budget Boost Instructions

Important Notes: Prior to beginning this or any installation read these instructions to familiarize yourself with the required steps and evaluate if you are experienced and capable to personally perform these modifications. A factory service manual should be used in conjunction with these installation instructions. Refer to the parts list to ensure that all necessary components and hardware has been included. If any parts are missing please contact your local TeraFlex dealer for assistance. For all tolerances not listed here refer to a factory service manual.

Tools needed: Basic mechanics tool set

36 mm Socket

For all Reverse Torx Sockets a 6 point socket can be used in its place. Size listed in () after each socket

E-14 Reverse Torx Socket (or 6pt 11mm)



T-40 Torx

Blue Thread Locker

Drill and 17/32 “ Drill Bit

#1351200

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ITEM # PART # DESCRIPTION QTY.

1 351210 Jeep Renegade Budget Boost Rear Aluminum Strut Spacer 2

2 351220 Jeep Renegade Budget Boost Front Aluminum Strut Spacer / Driver 1

3 351225 Jeep Renegade Budget Boost Front Aluminum Strut Spacer / Passenger 1

4 351231 Upper Charcoal Canister Relocation Bracket For Renegade, Aluminum 1

5 351241 Lower Charcoal Canister Relocation Bracket For Renegade Aluminum 1

6 351270 Control Arm Spacer for Renegade Budget Boost 2

7 753005 JK 3"-4" Front Quick Disconnect Swaybar Link w/ Upper Swivel Stud 2

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ITEM # PART # 1753100 RENEGADE HARDWARE & SPACER KIT QTY.

1 308 Grease Zerk 1/4"-28 UNF Straight 2

2 11396 Bolt, M10-1.25 X 45mm, EcoGuard, Hex Cap Screw 2


4 38622 Hardware, Bolt, M8-1.25 X 35mm / 10.9, Ecoguard 1

5 39623 Bolt, M10-1.5 X 50mm, EcoGuard, Socket Cap Screw 12

6 40357 Washer, M8 X 16mm OD, EcoGuard, Flat Washer 5


8 40359 Washer, 7/16" x 1.250" OD, Ecoguard, Flat Washer 8




12 90700 Nut, M6-1.0, EcoGuard, Flange Nut 3

13 37 Washer 1/2" Flat Zinc Plated 2

14 3801 Washer 3/4" x .124" Thick Flat Zinc Plated for QD Link Pin 2

15 477 Washer 1/2" Flat Stainless Steel 2

16 488 Nut 1/2"-20 UNF Stainless Nylock for QD4 SS 2

17 56-13-05-375-1-1 Spacer, 1.25" OD, 0.50" Length, .375" ID, Aluminum 6042-T5511H, No Finish 1

18 56-13-08-438-2-1 Spacer, 1.25" OD, 0.75" Length, .438" ID, Aluminum 6061-T6, No Finish 2



21 600499 Universal 3/4" Diamater Axle Side Quick Disconnect Stud 2

22 600503 5/8" Diameter Upper Quick Disconnect Parking Stud 2

23 600504 Quick Disconnect Bow Tie Pin 2

24 616 Nutsert 3/8"-16, .150-.312" Grip Length, Carbon Steel, Zinc Yellow Plus Lubricant 2

25 746 Nutsert Installation Tool for 3/8" Nutsert, Jeep Renegade 1

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Using a T-40 torx and an 18mm box end wrench, remove the

swaybar link from the strut.

Starting with the driver side front, detach the brake line and

the ABS wiring from the front strut.

Refer to the factory service manual for lift locations.

Raise and support the vehicle with jack stands. Note,

jack stands must not be under suspension

components.

Remove the tires and wheels.

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Front Install

Raise the hood. Note the orientation and remove wipers

using a 17mm.

Remove the 5 plastic clips that attach the cowl. Then remove

the cowl to gain access to the upper strut bolts.

Use a punch and hammer to bend the keyway nut tabs out of

the axle keyway. With a 36mm socket remove the axle nut.

Use a drift punch and hammer to partially separate the axle

shaft from the hub assembly to allow movement.

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To gain access to the all the strut bolts use a 10mm and re-

move the driver most and center bolts from the windshield

wiper assembly.

With an E-16 Reverse Torx and a 16mm, remove the 2 bolts

that attach the steering knuckle to the strut and separate.

Hint: A 6pt 14mm socket will work great if a E-16 R-Torx is

unavailable.

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Remove the 3 upper strut bolts with an E-14 Reverse Torx

(or 6pt 11mm) and remove the strut.

Hint: A 6pt 11mm socket will work great if a E-14 R-Torx is

unavailable. Note: Hold strut to keep it from falling.

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Install the front spacer (spacers are side specific, marked

with a R or L) on top of the strut. The open side of spacer will

be directly over the top of the knuckle facing out. Apply blue

threadlock and install the three 10M X 50mm allen head bolts

into strut through the recessed holes (no washers).

With a 8mm allen, torque bolts to 45 ft-lbs.

Mark the bottom back side of the strut 1/4” down. Cut or grind

off marked section of the strut. Spray paint exposed metal

black to match the shock.

Remove the other side of the factory swaybar link from the

swaybar using a T-40 torx and an 18mm box end wrench.

Install the new quick disconnect sway bar link stud into the

factory sway bar. Install M12 nylock nut onto the stud. Use a

6mm allen to hold the stud and use a 18mm to tighten the

nut. Torque 59 ft-lbs.

Outside of Jeep

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REST TEMPLATE ON EDGE OF BRACKET CENTER THIS HOLE ON

FENDER LINER STUD

DRILL HOLE HERE

Reinstall the knuckle to the strut. Note: If bolt holes do not

line up easily then tilt knuckle assembly back and start the

lower bolt first. Torque bolts 74 ft-lbs. + 90 deg.

Install axle nut.

Torque axle nut to 52 ft-lbs. + 63 deg. +/-2 deg.

and bend keyway tabs into axle keyways.

Re-install the strut, using the factory bolts into the

threaded bolt holes of the lift spacer. Apply threadlock

to bolts. The open section of the spacer will face the

outside of the Jeep. Note: This step will go easier with

a helper to hold the strut in place.

Torque to 45 ft-lbs.

Slide the upper end of sway bar link onto the stud.

Place 3/4” washer on stud and

insert Bow Tie Pin through hole on the end of stud.

Note: This should be a tight fit for better sway bar

function. Appling a bit of grease to the stud and

bushing will help with installation.

Insert the thicker 3/4” upper stud with smaller 1/2” stainless

steel washer onto the strut bracket, as shown. Install larger

1/2” washer and nylock nut onto the stud.

Torque to 59 ft-lbs.

Use template on second to last page of instructions to

mark location for swaybar pin nutsert.

Use a center punch to mark hole location and drill a

pilot hole. Next, drill hole out to 17/32”.

Remove the fender liner nut that is next to the ABS

bracket located on the frame. With a razor blade trim

corner of the front fender liner as shown.

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Outside of

Jeep

smaller larger

Ghosted spacer shown

to indicate orientation

remove

trim

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9/16”

5/8”

Rear Install

Remove the rear plastic inner fender liners. There

are five Philips screws, one plastic nut and four

10mm nuts.

Reinstall the two windshield wiper assembly bolts, the

cowl and the windshield wipers.

Inside the right fender, disconnect the charcoal canis-

ter wiring harness and hoses. Note: Push on the white

retaining rings to release hoses, push and squeeze

and to release connectors. Next remove the 3 nuts

using a 10mm and remove the canister.

Reattach brake and ABS lines to strut.

Repeat steps on the passengers side.

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Paint the hole to help prevent rust from forming. Use sup-

plied tool to install nutsert (5/8” wrench on base nut and

9/16 socket on the bolt). Use wrench to hold base nut and

tighten bolt with the socket. Once the nutsert is sufficiently

collapsed the bolt will feel tight. Check the nutsert for a solid

fit. Install 5/8” park stud into nutsert using a 9/16” wrench.

Loosen both lower control arms using an E-20 Reverse Torx

(or 6pt 16mm) and a 17mm. Do not remove the bolts.

With an E-14 Reverse Torx (or 6pt 11mm), remove the con-

trol arm bracket bolts from both brackets (4 per bracket).

Loosen

Remove

4 bolts

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Insert provided 1” spacers under the exhaust brackets and

install new M8 X 50mm bolt with washer (left and right sides).

Apply blue threadlock and use a 13mm to tighten.

REAR

While tightening M10 bolts press the control arm bracket

toward the rear of the Jeep. *See illustration below*

With a 19mm torque bolts 45 ft-lbs.

Install the control arm spacers using four M10 x 55mm bolts

(with blue threadlock), M10 (smaller) and 7/16” (larger) wash-

ers. Hint: Before installing the spacer start one bolt to help

hold it in place.

Larger washer goes up against control arm bracket.

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7/16” x 1.25” washers

M10 washers

Lower the sub-frame enough to install 1.5” spacers.

Install the supplied M14 x 150mm bolts and M14 wash-

ers and using a 22mm torque bolts to 100 ft-lbs.

Remove both bolts supporting the rear of the exhaust

with a E-14 Reverse Torx (or 6pt 11mm) (one on each

side).

Support the rear differential with a jack and remove the 4

subframe bolts with an E-20 Reverse Torx (or 6pt 16mm).

Do NOT tighten control arm bolts yet

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Mount the charcoal canister to the new brackets using factory

hardware and tighten the nuts. Re-attach the lines.

Remove the 3 upper strut bolts with an E-16 Reverse Torx

(or 6pt 14mm) and pull strut down out of the way. Install

spacer using 10M x 50mm allen head bolts, with blue

threadlock, into recessed holes (no washers).

With an 8mm allen torque bolts to 45 ft-lbs.

Install the upper charcoal canister bracket using the supplied

M6 nut, oriented as shown, and tighten nut

Remove bolts to brake/abs lines bracket. Insert provided 1”

spacers under bracket and install new M8 X 50mm bolt with

washer. Apply blue threadlock and use a 13mm to tighten.

Press Top of Strut to

Center

(see holes)

Re-install strut with the factory hardware using blue thread lock. Note: While tightening upper bolts press top of strut to-

ward the center of the Jeep. This will help with alignment. Torque upper strut bolts to 45 ft-lbs.

Repeat steps 31-33 for the other side.

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35 36

Install the lower charcoal canister bracket using the

supplied M6 nut, oriented as shown, and tighten nuts.

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Mark Pipe

Remove

Tab

Loosen the 2 bolts supporting the driveline carrier bearing

with a E-14 Reverse Torx. Remove one bolt and insert 0.75”

spacer under the support. Then loosely install the longer fine

thread M10 X 45mm bolt with a washer. Repeat for remain-

ing bolt and tighten with a 17mm.

Note about the Trail Hawk: The driveline skid will reinstall

without modifications. Carrier bearing support will contact the

skid with out issue.

Reinstall the rear fender liners.

Check to make sure all bolts and nuts are torqued according to specification (except for the control

arm bolts). Control arm bolt will be tightened once wheels are installed and Jeep is on the ground, at ride height. This will ensure that bushing load is in

a neutral position.

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For Trail Hawk Renegade Jeeps

Remove the rear bolt from the gas tank skid. Insert

provided 0.5” spacer under skid and install provided

M8 bolt with washer. Apply blue threadlock and use a

13mm to tighten.

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1/4”

1/2” to 3/4”

Forward

Note: On some late model Renegades the muffler may need

to be moved forward for additional bumper clearance. Skip to

step 41 if your muffler clears the rear bumper. If muffler is

close or contacting the bumper, loosen the exhaust clamp nut

(with a 15mm) that is just behind the front cross member.

If additional clearance is needed remove the bottom

two bolts from the rear bumper skin.

Mark and cut a 1/4” section off the end of both bolts.

Reinstall bolts back into rear bumper skin.

Mark current tailpipe position.

Using a hammer and chisel break off the indexing tap that is

just above the exhaust clamp. While working the tailpipe sec-

tion, push the rear section of the exhaust forward 1/2” to 3/4”.

Note: some penetrating oil will help if needed.

Tighten clamp nut with a 15mm.

Torque Exhaust Clamp Nut to 18 ft-lbs.

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Jeep is safe to drive but to avoid excessive tire wear an alignment is necessary and needs

to be done as soon as possible.

Note: Re-torque all components after 100 miles and inspect every 3000 miles after that.

Steel Wheels 63 ft-lbs 86 N-m

Aluminum Wheels 89 ft-lbs 120 N-m

Install the tires and torque lug bolts.

Lower Jeep to the ground.

With the Jeep on the ground torque all 4 lower

control arm bolts to 74 ft-lbs. + 90 deg.

REST TEMPLATE ON

EDGE OF BRACKET

CENTER THIS HOLE ON

FENDER LINER STUD

CUT OUT TEMPLATE

DRILL HOLE HERE

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TERAFLEX, Inc. 5680 West Dannon Way West Jordan, Utah 84081 Phone/801.713.3314 Fax/801.713.2313 www.teraflex.com

PRODUCT INFORMATION MAINTENANCE INFORMATION:

It is the buyer’s responsibility to have all suspension, drivetrain, steering, and other components checked for proper tightness and torque after the first 100 miles

and every 3000 miles after that.

NOTICE TO INSTALLER:

The enclosed “Warning to Driver” sticker must be installed in the vehicle in driver’s view. This sticker is to act as a constant safety reminder when operating the

vehicle. It is your responsibility as the equipment installer to install the provided sticker and to forward the product instructions to the vehicle’s owner for review. If a

“Warning to Driver” sticker or product installation guide were not included in the kit, FREE replacement stickers and instructions are available by request. It is the

installer’s duty to ensure a safe and controllable vehicle after the modifications have been performed.

WARNING:

Neither the seller nor the manufacturer will be liable for any loss, damage, or injury directly or indirectly arising from the use of or inability to determine the use of

these products. Before using, the user shall determine the suitability of the products for its intended use, and the user shall assume all responsibility and risk in

connection therewith.

WARNING TO DRIVER:

This vehicle has been modified to enhance off road performance and has unique handling characteristics. Use in harsh environments can cause extreme stress

on the components. Vehicle should be inspected after being off road to make sure that all the components are in working order and safe to travel on the highway.

All fasteners should be checked so that they are at the correct torque specifications as the vibration and stresses from off roading may cause critical fasteners to

work loose. Extra care should be taken to inspect the critical components, steering, and brake systems. During each oil change components such as arms, tie rod

ends, etc should be greased and checked for excessive wear. Any worn components should be replaced. When returning to the pavement always set or restore

tire air pressure to the factory recommendation and connect or engage any disabled sway bar mechanisms. Because of the higher center of gravity and larger

tires, this vehicle handles and reacts differently than many passenger cars, both on and off road. You must drive it safely! Extreme care should be taken to prevent

vehicle rollover or loss of control, which can result in serious injury or death. Avoid sudden sharp turns or abrupt maneuvers. Generally, braking performance and

capabilities are decreased when significantly larger/heavier tires are used, especially when used in combination with transfer case low-range blueuction kits. Take

this into consideration while driving. Do not add, alter or fabricate any factory or aftermarket parts to increase vehicle height over the intended height of the Tera-

Flex product purchased. Mixing component brand is not recommended. TeraFlex Inc. will not be responsible for any alteblue product or any improper installation

or use of our products. We will be happy to answer any questions concerning the design, function, and correct use of our products. It is ultimately the buyer’s

responsibility to have all bolts/nuts checked for tightness after the first 100 miles and then every 3000 miles. Wheel alignment, steering system, suspension and

drive line systems must be inspected by a qualified professional mechanic at least every 3000 miles.

TERAFLEX PRODUCT WARRANTY:

TeraFlex Inc. warrants TeraFlex Suspension products to the original retail purchaser to be free of defects in material and workmanship for as long as the original

purchaser owns the vehicle on which products were originally installed.

Failure to complete regular maintenance (grease every 3000 miles) on TeraFlex FlexArms will void this warranty. All other conditions of the standard TeraFlex

product warranty apply.

All TeraLow products are coveblue by the TeraFlex two (2) year warranty to be free of defects in material and workmanship for two years from date purchased.

TeraFlex axles are coveblue by a 12-month warranty to be free of defects in materials and workmanship.

This warranty does not cover or include product finish, improperly installed or applied products, improperly maintained products, products or components used for

racing or competition or damage due to abuse or neglect, products that fail due to the use of larger tire and wheel combinations.

All returns must be accompanied by an original invoice. It is the customer’s responsibility to remove the product from the vehicle. Shipping charges are the respon-

sibility of the customer. TeraFlex Inc. will pay the return freight if the product meets the terms of warranty.

This warranty is for the replacement or repair of defective TeraFlex products only and does not include freight charges, labor charges for removal of or installation

of TeraFlex or related products or components, costs incurblue due to down time of the vehicle, or lost profits due to vehicle down time.

A returned goods authorization number (RGA#) must accompany any returned products. For more information please contact a TeraFlex customer service repre-

sentative.

COPYRIGHT

©Copyright 2014. All rights reserved, TeraFlex Inc. Reproduction of this catalog and/or any of its contents without written permission is strictly prohibited.

TeraFlex® is a registeblue trademark of TeraFlex Inc. All trade names and logos including but not limited to TeraFlex, FlexArms, RockGuard, Monster, and

LCG are protected by law and duplication of trade names and/or logos are strictly prohibited.

TeraFlex Inc. reserves the right to update, discontinue, blueesign, modify finish, part number or component build parts if deemed necessary without written notice.

TeraFlex Inc., and any associated dealers are not responsible for misprints or typographical errors that may have inadvertently been made within this instruction

sheet.

Jeep® and the Jeep® grill are registeblue trademarks of Fiat Chrysler Automobiles N.V., and have no affiliation with TeraFlex Inc.

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renegade budget boost instructions - teraflex · 2017. 10. 23. · 1 revision b 999259 renegade...

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